Internal leakage in the heat exchanger at the inlet of the synthesis tower

It’s very likely that a further detailed analysis is needed; the sampling location must be accurate, and it’s also necessary to check whether there is an increase in system pressure and a decrease in the pressure difference between the inlet and outlet towers, among other factors

Have similar situations occurred in other factories? What usually causes them?

We have experienced internal leakage in the gas-gas heat exchanger, which means that a small portion of the gas takes a shortcut. But it wouldn’t go so far as to make the gas components at the inlet and outlet of the synthesis tower identical; what kind of severe internal leakage would that require?

What is the pressure difference at the inlet and outlet of the tower? I haven’t encountered this situation yet; the pressure difference experienced by the inlet and outlet heat exchangers is not high. Logically, even if two tubes were to break, the leakage rate shouldn’t be that significant. It is recommended to conduct another analysis of the gas composition. Also, how long has your catalyst been in use? ? There are many reasons for the decline in production. .

Is the heat exchanger at the inlet of the tower used for heat exchange with the gas exiting the synthesis tower, or is it heated by steam? If it’s the former, sampling at the same time shows that as long as there is a reaction, it’s almost impossible for the composition of the gas at the inlet and outlet to be identical. If they were almost the same, then it would mean no reaction is taking place. If it’s the latter, check whether the temperature at the inlet of the tower is too low; only in the case of almost no reaction would the composition of the gas at the inlet and outlet be the same, and that would also require an excess pressure. Analyze this along with the methanol production volume – the data you provided isn’t complete. You can compare the production volumes over time, as well as the gas composition over time, and list all details about the type of tower, so that it will be easier for others to help analyze the situation

The catalyst has been in use for almost two years; currently, the main issue is the decrease in production. Could you analyze other factors that affect methanol production?

H, CO, CO2, N2: Inlet values are 53, 24.26, 10, 10; outlet values are 52.2, 22.8, 10, 11. This is an analysis of the inlet and outlet conditions of the synthesis tower. The volume and pressure of the synthesis cycle remain roughly the same as before, but the output volume is low. Please analyze the reasons for this

To summarize roughly for reference only, the factors that generally affect synthetic yield include: 1. Catalyst activity. You have been using it for two years now; what is the temperature controlled in the catalyst bed? Have you mentioned the temperature? Are there many by-products? 2. Bed temperature 3. System pressure 4. Space velocity, system circulation rate 5. Gas composition. The hydrogen-to-carbon ratio at the inlet of the synthesis tower you mentioned is quite low; is this how operations are carried out all the time? 6. The cooling temperature before the separator should not be too high

The summary upstairs is good; generally, these are the factors at play

The hydrogen-to-carbon ratio is low, so the temperature needs to be increased in the later stages of catalyst use.